API-571 Mockup Test-02-Questions

Mockup Questions Test-2

1. The extent and degree of graphitization is usually reported in a--------------------

A. Quantitative
B. Qualitative
C. Informative
D. Semi-Quantitative

2. The two types of graphitization are

A. Localized and random
B. Nodular and spheroids
C. Planar and columnar
D. Acicular and needles

3. Graphite formation within the HAZ is called as

A. Nodular graphitization
B. Eyebrow graphitization
C. Planar graphitization

4. The temperature range which the economizer tubes most likely fail due to graphitization
is
A. 427C to 593C
B. 441C to 552C
C. 551C to 700C
5. Which mechanical property can be affected due to spheroidization
A. Tensile strength and ductility
B. Tensile strength and creep resistance
C. Load bearing strength and compression

6. At 552C, which micro structural change mechanism is likely to occur first in C-0.5Mo
steels and followed by next.
A. Spheroidization and followed by graphitization
B. Graphitization and followed by Spheroidization
C. Only Spheroidization
D. Only graphitization

7. ………………….is the reduction in toughness due to a metallurgical change that can

occur in some low alloy steels as a result of long term exposure in the temperature range
of about 650oF to 1100oF (343oC to593oC)
A. Temper embrittlement
B. Graphitization
C. Spheroidization

8. The equipment that is temper embrittled may be susceptible to brittle fracture during

A. Startup and Shutdown

B. During high temperature service
C. During operational upsets
9. ……………….. is a form of damage found mostly in older vintage carbon steels and C-0.5
Mo low alloy steels under the combined effects of deformation and aging at an
intermediate temperature.
A. Strain aging

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B. Temper embrittlement
C. 885 embrittlement
D. Softening
10. The effect of strain ageing is found in ………………with higher levels of nitrogen and
carbon than in………………
A. rimmed and capped steels, killed carbon steels
B. semikilled carbon steels, deoxidized
C. fine grain steels, coarse grain steels
11. Strain ageing is not common in steels manufactured with……………….
A. Coarse grain practice
B. Fine grain practice
C. Deoxidized steels
D. Semi deoxidized steels
12. ………….is most likely to occur in wall vessels manufactured from susceptible materials
that have not been stress relieved
A. Deformation
B. Strain aging
C. Cracking
D. Brittle fracture
13. Inspection methods to identify oxidation
A. pH & sulfur content monitoring
B. Temperature monitoring by thermocouples or IR
C. Ultrasonic thickness measurement for thickness loss
D. Both b & c
E. None of the above

14. Curve showing the effect of temperature on high temperature sulfidation of steels and
stainless steels
A. Nelson curve
B. McConomy curve
C. Giega-Miller curve
D. Couper-Gorman curve

15. Sulfidation of Iron-based alloys usually begins at metal temperatures above

A. 500 F
B. 800 F
C. 260 F
D. 1050 F

16. Significant increase of resistance to sulfidation can be achieved by

A. Increase of sulfur content
B. Increase of chromium content
C. Increase of carbon content
D. Decrease of carbon content
17. Metal dusting usually occurs in the operating temperature range of _____ and increases
with increase in temperature
A. 480 F to 800 F
B. 900 F to 1500 F
C. 1050 F to 1300 F
D. 427 F to 650 F

18. The damage mechanism which is primarily reported in the outlet piping of Methanol
reformer & Thermal hydrodealkylation is
A. Decarburization
B. Metal dusting
C. Flue gas corrosion

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D. Oxidation

19. Filtering of cooled furnace or reactor effluents may yield metal particles from upstream
which indicates probable damage of
A. Decarburization
B. Metal dusting
C. Flue gas corrosion
D. Oxidation
20. Alloys of -------------- family show improved resistance to Fuel Ash corrosion

A. Low alloy steels

B. 20 Cr – 18 Ni steels
C. 50 Cr – 50 Ni steels
D. Cu – Ni
21. Fuel ash corrosion for on water walls, cracks are pre-dominantly

A. Axial
B. Circumferential
C. Non directional
D. No cracks will occur
22. Due to fuel ash corrosion on water walls, similar to thermal fatigue cracks will occur,
temperature spikes by

A. 100 F (380 C)
B. 212 F (1000 C)
C. 176 F (800 C)
D. None of the above
23. The mechanism which forms a hard, brittle surface layer which develops on some alloys
due to exposure to high temperature process streams containing high levels of nitrogen
compounds such ammonia or cyanides, particularly under reducing conditions,

A. Hydriding
B. Nitriding
C. Carburizing
D. De-carburizing
24. Below alloys show improved resistance to Nitriding

A. Low alloys steels

B. Stainless steel 400 series
C. Nickel base alloys
D. Copper based alloys
25. Following are the materials which can be affected due to 885F embrittlement
A. 300 series SS WROUGHT & cast
B. 400 series SS
C. A&B
D. None of the above
26. Following are the critical factors for 885 embrittlement
A. Alloy composition, chromium content, amount of ferrite phase, operating
temperature
B. Alloy composition, thermal history, metal temperature, exposure time
C. Alloy composition, time and temperature
D. All of the above

27. refining companies limit the use of ferritic stainless steels to non-pressure boundary
applications because of the following damage mechanism
A. Temper embrittlement

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B. Sigma phase embrittlement

C. 885 embrittlement
D. All of the above

28. 885oF embrittlement is a metallurgical change that is not readily apparent with
metallography but can be confirmed through
A. Hardness testing while the equipment in service
B. Bend and impact testing by removing samples from service
C. Tensile testing
D. Both A&B

29. Following are the Preventative measures to minimize the potential for brittle fracture in
existing equipment
A. controlling the operating conditions
B. minimizing pressure at ambient temperatures during startup and shutdown,
C. periodic inspection at high stress locations.
D. All of the above

30. Reduction in the likelihood of a brittle fracture may be achieved by:

A. Performing a post weld heat treatment (PWHT) on the vessel if it was not
originally done during manufacturing;
B. if the vessel has been weld repaired/modified while in service without the
subsequent PWHT.
C. Perform a “warm” pre-stress hydrotest followed by a lower temperature hydrotest
to extend the Minimum Safe Operating Temperature (MSOT) envelope.
D. All of the above

31. Inspection is not normally used to mitigate

A. brittle fracture.
B. Temper embrittlement
C. Creep and stress rupture
D. All of the above
32. At high temperatures, time dependent deformation of stressed components is known
A. Sigma phase transformation
B. Rupture
C. Creep
D. None of the above
33. ---------------is the damage mechanism in which Permanent deformation occurring at
relatively low stress levels as a result of localized overheating.
A. Short term overheating- Stress Rupture
B. Thermal Fatigue
C. Corrosion fatigue
D. None of the above
34. Critical factors for short term overheating-stress rupture are
A. Time, Temperature and stress
B. Time and temperature
C. Time, temperature swing and frequency
D. Temperatue and stress
35. which part f the equipment is likely susceptible to Short term overheating
A. boiler tubes
B. fired heater tubes
C. both A &B
D. All of the above
36. Ruptures due to short term overheating are characterized by
A. Open fish mouth failures accompanied by thickening at the fracture surface
B. Open fish mouth failures accompanied by thinning at the fracture surface

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C. Bulging
D. None of the above
37. Piping affected by corrosion under insulation except
A. ASTM A 312 TP 304
B. ASTM A 106 Gr. B
C. ASTM A 335 P 11
D. Duplex stainless steel
E. None of the above
38. The upper temperature range where CUI can occur in marine atmosphere can be
significantly
A. 250 deg C
B. Less than 121 deg C
C. Above 121 deg C
D. Above 250 deg C
39. In a moist and wet environment, piping which protected by calcium silicate insulation,
pitting corrosion & stress corrosion cracking susceptibility is more in duplex steels than
300 series stainless steel
A. True
B. False
C. Duplex is more susceptible to pitting corrosion.
D. 300 series SS is less susceptible to pitting corrosion
40. The first few feet of a horizontal pipe run adjacent to the bottom of a vertical run is a
typical prone location for
A. Soil corrosion
B. Vibration fatigue cracks
C. Erosion corrosion
D. Corrosion under insulation
41. Following are the preventive measures taken to minimize thermal shock except
A. Install thermal sleeves to prevent liquid impingement on the pressure boundary
components.
B. Maximize rain or fire water deluge situations.
C. Review hot/cold injection points for potential thermal shock.
D. Prevent interruptions in the flow of high temperature lines.

42. For erosion and corrosion damage mechanism the metal loss rates depends upon the
following
A. velocity and concentration of impacting medium
B. the size and hardness of impacting particles,
C. the hardness and corrosion resistance of material subject to erosion, and the
angle of impact.
D. All of the above

43. For each environment-material combination, on what velocity above which impacting
objects may produce metal loss.
A. Threshold velocity
B. Impacting velocity
C. Erosive velocity
D. All of the above

44. Erosion-corrosion is a description for the damage that occurs when

A. corrosion contributes to erosion by removing protective films or scales,
B. erosion contributes to corrosion by removing protective films or scales,
C. Mechanical removal of surface material as a result of relative movement
between, or impact from solids, liquids, vapor or any combination thereof.
D. All of the above

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45. Protection from corrosion in the boilers is accomplished by maintaining a layer of

protective film of
A. Sulfide layer
B. Magnetite layer Fe3O4
C. 20% concentrated HNO3
D. Corrosion resistant paints
46. ---------------- is a form of erosion caused by the formation and instantaneous collapse of
innumerable tiny vapor bubbles.
A. Cavitation
B. Erosion
C. Erosion-corrosion
D. None
47. In a pump, the difference between the actual pressure or head of the liquid available
(measured on the suction side) and the vapor pressure of that liquid is
A. BPSH
B. NPSH
C. HPSH
48. --------------- damage generally looks like sharp-edged pitting but may also have a gouged
appearance in rotational components.
A. Erosion
B. Erosion-corrosion
C. Cavitation
49. “Rabbit ears” appearance of crack tips generally occur with a phenomenon of
_____cracking
A. Chloride stress corrosion cracking
B. Corrosion assisted cyclic stress cracking
C. Caustic stress corrosion cracking
D. Cracking due to corrosion under insulation
50. Caustic embrittlement is a form of stress corrosion cracking characterized by surface-
initiated cracks that occur in piping and equipment exposed to caustic, primarily adjacent
_______
A. HAZ of PWHT welds
B. Non PWHT welds
C. HAZ of welds
D. Root of welds.
51. Metals more resistant to caustic embrittlement
A. 300 series SS
B. 400 series SS
C. High chrome alloys
D. Nickel base alloys
52. Caustic embrittlement in solutions of NaOH & KOH is a function of
A. Caustic strength
B. Metal temperature
C. Stress levels
D. All of the above
E. None of the above
53. The damage mechanism often found in piping and equipment in H2S and mercaptan
removal units, H2SO4 and HF alkylation units that use caustic is
A. Chloride stress corrosion cracking
B. Caustic stress corrosion cracking
C. Sulfidation
D. SOHIC
54. Failures that have occurred in improperly heat-traced piping or equipment as well as
heating coils and other heat transfer equipment were often due to
A. Corrosion fatigue cracking
B. Caustic stress corrosion cracking

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C. Sulfidation
D. SOHIC
55. The pattern of cracking observed on the steel surface due to caustic embrittlement is
sometimes described as __________ , which often initiate at or interconnect with
weld-related flaws that serve as local stress raisers.
A. Rabbit ears
B. Spider web
C. Alligator hide
D. Crazy cracks
56. Caustic SCC in 300 series SS is typically _________ and very difficult to distinguish with
_________
A. Intergranular, Cl SCC
B. Intergranular, corrosion fatigue
C. Intragranular, Cl SCC
D. Intragranular, corrosion fatigue
57. Cathodic protection should be performed and monitored in accordance with NACE RP
0169
58. Localized corrosion due to the concentration of caustic or alkaline salts that usually
occurs under evaporative or high heat transfer conditions.
59. Material(s) primarily affected by caustic corrosion
A. CS, LAS
B. SS 300
C. Alloy 400 & Nicklel base alloys
D. Both a & b
60. __________ is most often associated with boilers and steam generating equipment
including heat exchangers, which this alkaline substance is used as neutralizer and/or
as a reactant.
A. Amine corrosion
B. Caustic corrosion
C. Phenolic (Carbolic acid) corrosion
D. Sour water corrosion
61. Exposure to high solution strength caustic can result in severe corrosion of carbon steel
& 300 SS above _____ and very high corrosion rates above _______, Alloy 400
and some other nickel base alloys exhibit much lower corrosion rates.
A. 150 F & 200 F
B. 175 F & 200 F
C. 75 F & 93 F
D. 200F & 250 F
62. _________ is a selective corrosion mechanism in which one or more constituents of an
alloy are preferentially attacked leaving a lower density (dealloyed) often porous
structure.
A. Oxidation
B. Dealloying
C. Decarburization
D. Carburization
63. Primary materials affected by Dealloying in stagnant water conditions.
A. Copper alloys (Brass)
B. Alloy 400
C. Cast Iron
D. All of the above.
64. In cooling water applications, heat exchanger tubing (brass, Al brass) is susceptible to
_________ in some brackish and seawater applications but often the tube sheets
suffer significant damage.
A. Cooling water corrosion
B. Sea water corrosion
C. Erosion – Corrosion

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D. Selective leaching
65. To inhibit Dealloying in copper alloys tin is added, similarly addition of little amounts of
_____________in admiralty brass will tends to inhibit Dealloying
A. Potassium
B. Silicon
C. Manganese
D. Phosphorous
66. Materials affected to Hydrogen embrittlement
A. CS & LAS
B. 400 series SS
C. PH-SS (Precipitation hardenable)
D. High strength Ni base alloys
E. All of the above
67. If wet electrodes or high moisture content flux weld electrodes are used, hydrogen can be
charged into the steel and can cause ___________ in welds
A. Corrosion
B. Delayed cracking
C. Blistering
68. To result hydrogen embrittlement in steels, hydrogen can come from Cathodic protection
A. True
B. False
69. “Hydrogen flaking” is the phenomenon occurs during
A. Welding process (Joining practice)
B. Manufacturing process (Melting practice)
C. Cutting process (Grinding / Sawing practice)
D. Hydropower generating process
70. Hydrogen embrittlement in steels is prominent at temperatures from ambient to about
_________ and effects decrease with increasing temperature.
A. 150°F
B. 200°F
C. 300°F
D. 450°F
71. Hydrogen embrittlement is not likely to occur above
A. 180 F to 220F
B. 160F to 180F
C. 220F to 240F
D. 120F to 140F
72. Thick wall steel components are __________ vulnerable to hydrogen embrittlement due
to increased thermal stress and high restraint.
A. Less
B. More
C. Not
73. As steel strength increases, susceptibility to Hydrogen embrittlement __________.
Certain microstructures, such as untempered martensite and pearlite, are more
susceptible at the same strength level than tempered martensite. Carbon steel
that is severely hydrogen charged will have _________ toughness than with no
hydrogen.
A. Decreases, Higher
B. Increases, Lower
C. Increases, Higher
D. Decreases, Lower
74. Carbon steels or Low alloy steels are subjected to excessive corrosion when exposed to any
concentration of HCL acid that produces PH levels

A. Below 5.6
B. Below 4.5

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C. Below 7.0
D. None of the above

75. The presence of oxidizing agents (oxygen, ferric and cupric ions) in HCL environments will
increase the corrosion rate, particularly for alloy 400 and Alloy B-2.

76. Titanium performs well in oxidizing conditions but fails rapidly in dry HCl service

77. Damage in refineries is most often associated with dew point corrosion in which vapors containing
water and hydrogen chloride condense from the overhead stream of following areas.

A. Distillation, fractionation or stripping tower, atmospheric tower overheads

78. Sulfidation or High temperature H2/H2S corrosion takes place at temperatures

A. >300 degF
B. >400 degF
C. >500 degF
D. >600 degF

79. Sulfidation mainly occurs due to

A. CO2
B. H2S
C. H2SO4
D. None of these

80. Sulfidation accelerates due to the presence of

A. HCL
B. Hydrogen
C. H2SO4
D. None of these
81. following are the materials affected due to H2S corrosion in the order of increasing
resistance
A. carbon steel, low alloy steels, 400 Series SS, and 300 Series SS.
B. carbon steel, low alloy steels, 300 Series SS, and 400 Series SS.
C. low alloy steel, carbon steels, 400 Series SS, and 300 Series SS.
D. None of the above
82. The major factors affecting high temperature sulfidation are
A. the temperature, the presence of hydrogen, the concentration of H2S and the
alloy composition.
B. the temperature, the presence of hydrogen, the concentration of H2S and Ph
C. the temperature, the presence of hydrogen ion concentration, the concentration
of H2S and the alloy composition.
D. All of the above
83. Corrosion will appear as a uniform loss in thickness from the process side and is
accompanied by the formation of an
A. iron sulfide scale.
B. Iron carbide scale
C. Iron sulphate scale
D. Iron chromate scale
84. When inspecting a piping which is in sulfur service, a tightly adherent shiny gray scale
attached to the surface is observed uniformly. What is the mst likely damage mechanism
can occur
A. HTHA
B. Sulfidization

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C. Oxidation
D. Fuel ash corrosion
85. Overhead piping circuits should be designed for a maximum velocity of ________in the
recovery section to prevent carbolic acid corrosion. (Phenolic acid corrosion)
A. 10 fps
B. 20 fps
C. 30 fps
D. 15 fps
86. Recovery tower overhead temperatures should be maintained to at least ____F, ___ the
dew point.
A. 60 F above
B. 30F below
C. 60 F below
D. 30 F above
87. Generally ________ material is used to resist phenolic acid corrosion in phenol flash
towers and condenser shells and separators, but in the areas of high velocity ________
material is superior.
A. Carbon steel, SS 316
B. SS 316, Alloy C276
C. Alloy C276, Alloy 400
D. Low alloy steel, SS 316.
88. ER corrosion probes and corrosion coupons have been used for corrosion monitoring of
A. Phenolic acid
B. Napthenic acid
C. Hydro fluoric acid
D. Both a & b
E. All of the above.
89. During inspection of amine service following areas of unit should be concentrated

A. Hot
B. Cold
C. Ambient

90. Amine Corrosion is more aggressive in this kind of amine solution and Amine stress
corrosion cracking is more susceptible in this kind of amine solution

A. Lean amine, Rich amine

B. Rich amine, Lean amine
C. Rich amine, Rich amine
D. Lean amine, Lean amine

91. Following material is highly susceptible to Amine cracking/Carbonate cracking

A. Carbon steels
B. Low alloy steels
C. Stainless steels
D. Both a & b

92. Cracking in rich amine service mainly associated with

A. Amine SCC
B. Wet H2S damage
C. Carbonate SCC
D. Hydrogen SCC

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93. Likelihood and severity of Amine cracking increases with

A. Temperature
B. Stresses
C. Temperature and stresses
D. None of the above

94. With increase in amine concentration Severity of cracking ____

A. Increases
B. Decreases
C. No significant effect
D. None of the above

95. Amine cracking is typically develops ____

A. Parallel to the weld, In weld metal cracks are either transverse or longitudinal
with the weld

96. Amine cracking mostly takes place at

A. HAZ or adjacent to HAZ

B. Weld metal
C. Base metal
D. All of the above
97. Primary purpose of Phenol(Carbolic acid) is

A. To remove aromatic compounds from lubricating oil feed stocks

98. Following materials are resistant to Carbolic acid corrosion

A. SS316L for low velocity, Alloy C276 for reasonably high velocity or other
locations where 316L is in adequate

99. Phenol corrosion is normally less when the temperatures are

A. <1500F
B. <2500F
C. <3500F
D. <4500F

100. Carbon steel and 304/304L stainless steel corrode rapidly in phenol service when
temperatures are

A. <1500F
B. <2500F
C. <3500F
D. <4500F

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101. Phosphoric acid is used as catalyst in this unit

A. FCC
B. Polymerization
C. Fractionation
D. Treating

102. Phosphoric acid corrosion results in

A. General corrosion
B. Cracking
C. Pitting or Localized corrosion
D. None of the above

103. Primary concern of phosphoric acid corrosion is

A. Increase in Water
B. Increase in phosphoric acid concentration
C. Decrease in water
D. None of the above

104. Phosphoric acid corrosion: Type 304L SS is satisfactory for phosphoric acid
concentration of 100% up to about 120oF (49oC). Type316L SS is required from 120oF
to 225oF (49oC to 107oC)). Type 316L SS and Alloy 20 are effective at concentrations
up to 85% at boiling temperatures.

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